Hydrocarbon Processing - February 2021 - 75

Environment
and Safety
J. A. KLEIN, ABSG Consulting Inc.,
Knoxville, Tennessee

Implement effective operational discipline programs
to improve process safety performance-Part 1

sys
tem

s

e

plin

ent
gem
ana

Effective
programs

isci
al d

on
rati

Precursors to implementing OD. Precursors to implementing OD programs
include:
* Recognizing and assessing hazards
* Implementing risk management
programs.
It is necessary to know what hazards
may be present to develop appropriate
risk management requirements, so initial
and continuing efforts to identify and
assess hazards in the workplace define
the type and level of risk management
program needed.2,6 If the hazards are not
identified and assessed properly, how can
appropriate safeguards and systems be
implemented and maintained to manage
the risks associated with those hazards? If
process hazards, such as toxicity or flammability, are present, then a process safety
program is needed. Depending on the actual level of risk, the quantity of hazardous materials present, intrinsic hazards,
processing conditions, reactions and
other factors, the requirements of a process safety program may vary and may or
may not require regulatory compliance,
such as with the Occupational Safety and
Health Administration's (OSHA's) process safety management standard or other
regulations. Occupational safety, industrial hygiene, environmental protection and
other programs may also be required to
help ensure all hazards are appropriately
identified and managed.
As shown in FIG. 1, effective safety programs consist of three interrelated foundations2 comprising:

1. Safety culture and leadership-
Safety culture and leadership
help define how an organization
approaches and prioritizes
problems and issues related to
managing safety.2,7 Is safety a
core value with high priority
in all cases, or is it more of an
afterthought, subject to potentially
conflicting organizational
priorities such as cost or
productivity? Safety culture
influences the daily behaviors of
leadership and workers, who either
reinforce and improve the culture
over time or allow it to degrade.
Safety culture and leadership are
part of the overall organizational
culture that encompasses all the
ways work is or should be done, as
well as how it is impacted by safety
considerations and requirements.
In a weak safety culture, or
with unaligned leadership,
implementation of effective safety
programs is often constrained, and
achievement of excellent safety
performance is difficult.

Saf
ety
m

excellent safety performance. Steps for
getting started in implementing an OD
program, or improving an existing effort,
are discussed here.

Ope

Operational discipline (OD) describes
human behavior in complying with required systems, every time, to consistently
achieve organizational goals and overall
operational excellence.1,2 While a focus on
OD is not a panacea, OD is a fundamental part of effective programs for achieving excellent performance in process
safety, environmental, health and safety
programs, quality, reliability and productivity.2,3,4 Well-designed management systems are only the first step; the disciplined
efforts of involved personnel in effectively
implementing and following system requirements continuously are also needed.
Failing to follow a system requirement-
even just once-due to a human performance issue, inattention, complacency
or other reason, can result in significant
consequences, such as personal injury, environmental harm and business loss.
For example, an incident investigation
by the U.S. Chemical Safety Board (CSB)5
concluded that an operator opened the
bottom valve of an operating polymerization reactor, apparently bypassing an
active pressure interlock, instead of the
intended action of opening the bottom
valve of a nearby reactor that was being
cleaned. The resulting large release of hot,
flammable material from the operating
reactor ignited, leading to five fatalities
and major damage to the facility. While
the U.S. CSB investigation identified several other design and operating issues, human errors like this must be anticipated
and appropriate safeguards provided to
help prevent serious injuries and other
significant consequences. Focusing on
OD-doing the right thing, every time-
is an essential component of maintaining
effective safety programs and achieving

Safety culture/leadership
FIG. 1. Foundations of an effective safety
program.2
Hydrocarbon Processing | FEBRUARY 2021 75



Hydrocarbon Processing - February 2021

Table of Contents for the Digital Edition of Hydrocarbon Processing - February 2021

Contents
Hydrocarbon Processing - February 2021 - Cover1
Hydrocarbon Processing - February 2021 - Cover2
Hydrocarbon Processing - February 2021 - Contents
Hydrocarbon Processing - February 2021 - 4
Hydrocarbon Processing - February 2021 - 5
Hydrocarbon Processing - February 2021 - 6
Hydrocarbon Processing - February 2021 - 7
Hydrocarbon Processing - February 2021 - 8
Hydrocarbon Processing - February 2021 - 9
Hydrocarbon Processing - February 2021 - 10
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Hydrocarbon Processing - February 2021 - 27
Hydrocarbon Processing - February 2021 - 28
Hydrocarbon Processing - February 2021 - 29
Hydrocarbon Processing - February 2021 - 30
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Hydrocarbon Processing - February 2021 - 33
Hydrocarbon Processing - February 2021 - 34
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Hydrocarbon Processing - February 2021 - 36
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Hydrocarbon Processing - February 2021 - 40
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Hydrocarbon Processing - February 2021 - 63
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Hydrocarbon Processing - February 2021 - 73
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Hydrocarbon Processing - February 2021 - 75
Hydrocarbon Processing - February 2021 - 76
Hydrocarbon Processing - February 2021 - 77
Hydrocarbon Processing - February 2021 - 78
Hydrocarbon Processing - February 2021 - 79
Hydrocarbon Processing - February 2021 - 80
Hydrocarbon Processing - February 2021 - 81
Hydrocarbon Processing - February 2021 - 82
Hydrocarbon Processing - February 2021 - 83
Hydrocarbon Processing - February 2021 - 84
Hydrocarbon Processing - February 2021 - GP-1
Hydrocarbon Processing - February 2021 - GP-2
Hydrocarbon Processing - February 2021 - GP-3
Hydrocarbon Processing - February 2021 - GP-4
Hydrocarbon Processing - February 2021 - GP-5
Hydrocarbon Processing - February 2021 - GP-6
Hydrocarbon Processing - February 2021 - GP-7
Hydrocarbon Processing - February 2021 - GP-8
Hydrocarbon Processing - February 2021 - GP-9
Hydrocarbon Processing - February 2021 - GP-10
Hydrocarbon Processing - February 2021 - GP-11
Hydrocarbon Processing - February 2021 - GP-12
Hydrocarbon Processing - February 2021 - GP-13
Hydrocarbon Processing - February 2021 - GP-14
Hydrocarbon Processing - February 2021 - GP-15
Hydrocarbon Processing - February 2021 - GP-16
Hydrocarbon Processing - February 2021 - GP-17
Hydrocarbon Processing - February 2021 - GP-18
Hydrocarbon Processing - February 2021 - GP-19
Hydrocarbon Processing - February 2021 - GP-20
Hydrocarbon Processing - February 2021 - GP-21
Hydrocarbon Processing - February 2021 - GP-22
Hydrocarbon Processing - February 2021 - GP-23
Hydrocarbon Processing - February 2021 - GP-24
Hydrocarbon Processing - February 2021 - GP-25
Hydrocarbon Processing - February 2021 - GP-26
Hydrocarbon Processing - February 2021 - GP-27
Hydrocarbon Processing - February 2021 - GP-28
Hydrocarbon Processing - February 2021 - GP-29
Hydrocarbon Processing - February 2021 - GP-30
Hydrocarbon Processing - February 2021 - GP-31
Hydrocarbon Processing - February 2021 - GP-32
Hydrocarbon Processing - February 2021 - GP-33
Hydrocarbon Processing - February 2021 - GP-34
Hydrocarbon Processing - February 2021 - GP-35
Hydrocarbon Processing - February 2021 - GP-36
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2024-v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2024
https://www.nxtbook.com/gulfenergyinfo/gulfpub/gas-processes-handbook-2022_v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/gas-processes-handbook-2022
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hp_202212
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2023-v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2023
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hp_202211
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202210
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_202109
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202108
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_processes_handbook_2021_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_processes_handbook_2021
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202107
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_202101
https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202012
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202011
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202010
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2021
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202009
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202008
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202007
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202006
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202005
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_202002
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202001
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201912
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201911
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201910
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201909
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201908
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201907
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201906
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201905
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201904
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201903
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201902
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201901
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201812
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201811
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201810
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201809
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201801
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201712
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201711
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201710
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201709
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201708
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201707
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201706
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201705
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201702
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201701
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2017mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201612
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201611
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201610
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201609
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201608
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201602
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201601
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201512
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201511
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